Knitted carpet



H. S. LEYBOURNE KNITTED CARPET Filed March 28, 1960 ilnited StatesPatent Ofifice 3,65 6,513 Patented Dec. 4, i62

3,066,513 KNITTED CARPET Harold S. Leyhourne, Wiilowdale, Ontario,Canada, as-

signor to Texama Limited, Toronto, Ontario, Canada, a corporation ofOntario, Canada Filed Mar. 28, 1960, Ser. No. 18,128 1 Claim. (Cl.66--10) This invention relates to improvements in floor coverings orcarpets.

More particularly, the invention relates to a knitted floor covering orcarpet having a durable resilient backing of sponge rubber or likematerial.

It is believed that the particular floor covering described herein hasnever been successfully accomplished before. An aspect which makes itparticularly feasible and attractive to the consumer is the addition ofthe foam rubber or similar backing.

The main disadvantage in the provision of the thick living room orexecutive type of carpet presently obtainable is decidedly one ofexpense. Carpets of this type are almost out of reach of the averagemans income at the present time.

The present invention is comparatively cheap and extremely useful. It isalso wear resistant and will fill a public need from the standpoint ofeconomy.

Therefore, an object of this invention is to provide the combination ofa knitted carpet having a resilient backing of sponge rubber, or thelike, which will also act to prevent slipping or creeping of the carpet.

According to the present invention a floor covering or the likecomprises an intermediate ply of a weft knitted fabric defining asurface backing ply, a surface ply or layer of pile yarns laid in onesurface of the weft knitted fabric, there being at least two pile yarnsinterconnected to each course of the knitted fabric, without beingknitted, at spaced points along the course, and a base layer integrallycombined or bonded with the opposite surface of the weft knitted fabric.The pile yarns are raised and define a pile surface on the side of theintermediate layer or pile opposite the base layer.

There is no special novelty residing in the process involved in theproduction of the present invention or the machinery employed in theprocess. Applicant has knitted a circular knitted fabric with the kindsof materials normally used in carpets rather than the kinds and typesnormally used on knitting machines. This is believed to be a completedeparture from the previous uses of a circular knitting machine.

In the process of producing the present invention, it has been foundpreferable to obtain a blend comprising approximately 70% nylon and 30%rayon. This ratio provides an end product which Wears particularly welland has a very good appearance. Having obtained this ratio the blendedfibres are then subjected to a carding process. This process will bewell known to a man skilled in the art.

Following the carding process the blended fibers in the form of strandsof material are wound onto spinning frames and subjected to a cone'winding process. At this stage of the process, the individual blendedstrands of fibres are wound onto separate cone shaped holders. The fibreholding cones are then set up on a conventional circular knittingmachine along with a series of cotton holding cones. The circularknitting machine operates in a manner well known to a man skilled in theart. The presence of the cotton in the knitting process provides aknitted fabric having a cotton backing in which the nylonrayon yarns areincorporated without being themselves knitted. Nylon or acrilon may alsobe used to provide an intermediate ply or backing instead of cotton. The

circular knitted fabric is then subjected to a scouring or cleansingtreatment after which the fabric is opened to a fiat width forprocessing. This step is followed by a napping operation or pile rising,and it is one in which care must be given in order to obtain the fullrich cover desired and needed for the end use of the fabric. The lengthof the pile is then established by a close shearing or cropping processin order to obtain the desired pile height.

The accompanying drawing shows how the layin is formed in the loops inthe knitting process. The pile yarns are designated A and define thesurface ply while the knitted threads of the weft knitted fabric aredesig nated B and are of 1/ l6s carded cotton dyed to resemble, asnearly as possible, the facing of the finished carpet. As has been saidthe layin A is made up of a blend consisting of approximately nylon and30% rayon. The rayon is dope dyed and the nylon kettle dyed. Thisunusual blending of fibres prepared on the conventional woolen yarnsystem yields a thread which is very strong, lofty and adapts itself tofuture operation and end result.

It will be appreciated that various other fibres, ratios and blends maybe employed, for instance, mohair or any synthetic or animal fibre maybe used but it has been found that a ratio of approximately 70% nylonand 30% rayon produces the best results.

An important feature in the manufacture of the invention is the mannerin which the cotton back and the pile yarns, which are the face, areinter-connected, thus forming a firm fabric 'which will withstand theaction of raising the pile.

The foam rubber backing or base layer C may be applied directly to theback of the fabric and spread by means of a doctor blade. The foam isthen cured on the fabric in drying ovens. A sponge rubber could also beemployed as the backing or base layer C for the knitted carpet and inthis event it would be applied by a calender roll.

The nature of the backing layer C may vary with the preference of themanufacturer. While a wide variety of plastics and elastomers may beused such as rubber and synthetic rubber in unaerated form, polyvinylchloride, and the like, it has been found best to employ aeratedplastics and elastomers such as sponge or foam rubber.

It will be understood that the employment conditions of vulcanizing willdepend on the character of the backing material which is employed.

A sponge or foam backing produces a very desirable resiliency in thetread of the carpet.

The sponge rubber backing or base layer C may also be applied to theunderside of the cotton backing by vulcanized rubber cement or by anyother suitable adhesive. In this event, the fabric is first knitted asdescribed and then the backing is coated with an application ofcementitious binding material. The sponge rubber layer C which has beencut to size is then applied to the cement and the cement is allowed toset for a reasonable period to secure adhesion. After vulcanization, thecomposite carpets are trimmed to exact size as required.

It may be restated in conclusion that during the knitting and finishingprocess of the fiber yarns, the blended pile yarn is combined with theintermediate ply of knitted cotton strands after which the resilientbase layer or ply is integrally bonded to form a finished carpet beingof fine appearance, resilient, and extremely wear resistant.

I claim:

A floor covering or the like comprising: a fiat intermediate plyincluding a weft knitted fabric having courses and wales, a surface plyon one side of said weft knitted fabric and including at least two pileyarns laid in each course of said weft knitted fabric, one of said twopile yarns of each course being interconnected to the course withoutbeing knitted at spaced points along the course and the other of saidtwo pile yarns of each course being interconnected to the course'Without being knitted at spaced points along the same and at spacedpoints from the points of interconnection of said one pile yarn, saidpile yarns being raised and defining apile surface for the floorcovering, and a resilient base layer ply integrally bonded to theopposite side of the Weft knitted fabric.

References Cited in the file of this patent UNITED STATES PATENTS BellisJune 9, 1896 Hall Oct. 30, 1945 Dildilian Aug. 23, 1949 Rice Nov. 28,1950 Stahl Dec. 23, 1952 Deiss et al June 3, 1958

